Conductor stringing apparatus and process

ABSTRACT

A line stringing apparatus includes in combination an electric motor, motor controller and a processor switchable between a pulling mode and a tensioning mode. An electric motor expends electrical energy when pulling the line and generates electrical energy when tensioning the line. The processor outputting commands to the motor controller for control thereof and for application of electrical energy from the batteries to the electric motor when in the pulling mode and for application of electrical energy generated by the electric motor to the plurality of batteries when in tensioning mode. The processor limits electric motor torque and speed based on operator commands for speed and torque in said pulling mode; and, the processor controlling electric motor torque in the tensioning mode.

FIELD OF THE INVENTION

The invention is in the field of conductor stringing apparatuses andprocesses.

BACKGROUND OF THE INVENTION

High voltage utility transmission lines are capable of supplying powerover tens or hundreds of miles (or further) with minimal losses becauseof the very high voltages used. Step-up transformers located at utilitypower generation plants boost the voltage transmission levels up,depending on the particular utility, to and beyond 745 kV AC. At highvoltages, power can be transmitted effectively as power transmission isa function of voltage times the current times the cosine of the phaseangle between the voltage and the current. Use of high voltage minimizescurrent in the lines which thus minimizes losses which can be generallyexpressed as current squared times the resistance of the transmissionline (i.e., the conductor).

Electrical demand in the United States and worldwide has steadily grown.Larger and more conductors are needed. Utilities constantly upgradetheir systems at choke points in the grid to add new conductors and/orto replace existing conductors with new conductors which may be able tocarry more current. Conductor stringing apparatuses and processes areused between utility towers or poles which may be separated by largedistances, for example, they may be a quarter of a mile to a half a mileapart.

In a conductor stringing operation, a device called a conductor or cablepuller-tensioner is used. Two machines are necessary. One of themachines functions as a puller which supplies the energy to pull theconductor against the friction of fixtures on the poles, against theforce of the cable by virtue of its mass and the earth's gravitationalattraction (i.e., its weight) and against the resistance supplied by theother machine which functions as a tensioner. The tensioner is anecessary part of the equipment and process lest the cable/conductorwould sag and get tangled up with foliage, trees or other structureslocated beneath the cable/conductor path.

Previously, a drum puller/tensioner was typically powered by an internalcombustion engine driving a hydraulic pump. The resulting pressure andflow in the hydraulic system coupled with a mechanical gear reducerwould rotate the drum at the specified torque and speed. Tensioning washydraulically controlled. As the pulling rope began to rotate the drum,it created pressure in the hydraulic system that could be adjusted tocreate the desired line tension.

U.S. Pat. No. 3,326,528 to S. S. McIntyre entitled Cable Stringing andTensioning System discloses at col. 3, Ins. 34 et seq. “the operator ofthe vehicle initially energizes the stator coils with current that maybe supplied from a storage battery 50. Eddy currents are then generatedby the relative motion of rotors and stator that produce a magneticfield in the rotors. This tends to retard rotation of the rotors andshaft 40, and this retarding force on shaft 40 builds up through thetrain of gearing . . . and is transferred back therethrough the sheaves. . . to resist their turning for braking the outfeed of transmissioncable thereover.”

Many high voltage utility transmission lines are located in or nearcities. Some of these lines require periodic replacement and/or upgradeand considerable noise and pollution is generated by internal combustionengines which power existing conductor stringing puller-tensioners. Thenoise and pollution present nuisances for those living in proximity tothe high voltage transmission lines. It is, therefore, desirable to havea conductor stringing apparatus which is environmentally compatible andefficient.

SUMMARY OF THE INVENTION

An electric drive system powered by an on-board battery bank to run adrum puller-tensioner used in the utility industry is disclosed andclaimed. Further, a multi-drum puller-tensioner or bullwheel tensionermay be used employing the principles expressed herein. The battery bank(renewable energy storage) is to be of sufficient voltage and capacityto allow operation for a minimum of two hours at maximum rated torqueand speed. Tensioning is achieved by magnetic coupling of the rotor andstator of the electric motor. Although it is preferred to use analternating current motor it will be understood by those skilled in theart that a direct current motor may be used. Energy produced duringtensioning is stored in the battery bank or converted to heat by aresistor bank and can be maintained indefinitely at the maximum ratedtension and line speed. It was determined that an electrical solutioncould be applied to replace the internal combustion engine andhydraulics that are traditionally used in hydraulic puller-tensioner.The benefits of the instant invention include zero emissions and extremereduction in noise.

There are three electrical circuits used in the puller-tensioner. First,the main high voltage circuit operates nominally at 180 volts dc andsupplies the electric motor after being converted by the motorcontroller to three phase alternating current power. Twelve (12) andtwenty-four (24) volt dc circuits are used for accessory components.

The high voltage power source is comprised of thirty 30 deep cycle 12volt batteries that are rated at 150 amp-hours each. “Amp-hours” is ameasure of electric charge. One Amp-second is equal to one coulomb. OneAmp-hour is equivalent to 3600 coulombs of electric charge. Fifteen(15), 12 volt dc batteries are wired in series to form the nominal 180volt dc circuit. Two of the fifteen, 12 volt battery strings are wiredin parallel resulting in a 180 volt power supply with a 300 amp-hourcapacity. Trojan T-1275, 12 volt dc, lead acid deep cycle batteries witha 150 amp-hour capacity are the preferred batteries.

When fifteen (15) Trojan T-1275 batteries are wired in series theycombine for a total of 180 VDC. When two strings of 15 batteries areconnected in parallel they double the capacity to 300 amp hours. At thisvoltage, the maximum amp draw will be about 115 amps to supply a 20.7 kWload. The maximum current draw will be reached close to the end of aconductor stringing operation.

The batteries store enough energy to operate the unit for two hours andthe combined voltage of the batteries is in the range required by themotor/controller. Any energy storage device that does this would besuitable. In other words, it is specifically contemplated that otherbattery types such as Lithium Ion and/or Nickel Metal Hydride may beused. Energy storage devices such as capacitors may also be used. Pricebeing a factor, deep cycle lead acid batteries are used. Lead acidbatteries give the most energy storage per dollar.

The electric motor is a 3-phase AC motor and rated for 34 kW. Whenpulling, the motor controller converts the 180 volt direct currentenergy from the batteries into alternating current to drive the motor.When tensioning, the motor controller converts the alternating currentenergy produced by the motor to direct current energy that is eitherstored in the batteries or converted to heat by the resistor bank.

The resistor bank is rated for 20 kW and is controlled by pulse widthmodulation. In the tension mode, electric energy is produced by themotor from higher tension and speed, more energy is allowed to bedissipated by the resistors. This is automatically controlled in theCAN-Bus program by monitoring battery voltage and adjusting the pulsewidth modulation accordingly which controls relay contacts, a solidstate relay containing no moving parts, or and insulated gate bipolarrelay containing no moving parts.

Converters are used to create constant twelve (12) and twenty-four (24)volt dc supplies from the high voltage circuit (180 volt dc) forsupplying energy at the appropriate voltages to the accessories. The 180volt system is charged using a custom, on-board, high voltage chargerthat is specifically designed for the batteries that are being used.There are a couple of companies that manufacture chargers specificallyfor the Electric Vehicle industry that would be appropriate. Based onprice and ease of use, the Zivan NG-5 was chosen. It requires a 30amp-230 VAC source and can charge a fully discharged battery pack in 10hours. This charger was preprogrammed by the manufacturer for thespecific battery used to ensure the proper charge curve for longerbattery life. Other chargers may be adapted for use.

Alternatively, fresh batteries may be brought to the machine on atrailer if longer usage times are desired. If the customer believes theyneed that option, a small additional trailer with a set of batteriespre-wired may be supplied. Then it is a matter of unplugging the oneplug that connects the onboard batteries to the circuit and plugging inthe auxiliary batteries.

There are several secondary devices that are needed for fullfunctionality. A custom electric brake is used in conjunction with theelectric drive. The electric brake is able to supply a braking torque of150 ft-lbs or, expressed another way, 1800 in-lbs. When the speedreduction of 67.642 of the sprockets and gearbox are considered theelectric brake provides approximately 121,755 inch-lbs of resistivetorque. The torque is sufficient to hold the pulling reel at maximumline pull when the machine is manually or automatically shut down. Thelevel wind is powered by a Duff-Norton electro-mechanical cylinder.

Controlling the unit is a Parker IQAN-MD3 Master Module (hereinaftersometimes referred to as the “processor”). A CAN program was writtenusing the IQAN Design which integrated all the components with theParker IQAN MD-3. This allows communication with the Azure Dynamics,Inc. DMOC motor controller so that speed and torque can be controlled byuser inputs. Safety features are included in the program and aredesigned to warn the user when unsafe parameters exist and safely shutdown the machine when necessary.

The processor, its modules and the monitors require twelve (12) andtwenty-four (24) volt dc sources. To obtain these voltages required bythe controllers and monitors, a dc-dc voltage converter is used toconvert the 180 volt dc circuit into lower voltages. A dc-dc converterwas chosen from Metric Mind Engineering that produces 45 amps at 12volts. The dc-dc converter keeps a single 12 volt battery charged thatis dedicated to the 12 volt circuit and is used to power all secondarycontrol devices and monitors.

A conductor stringing apparatus includes a frame and a conductor reelabout which the conductor is wound. An electric motor is affixed to theframe and coupled to the conductor reel. The electric motor expendselectrical energy when pulling the conductor in the pulling mode and theelectric motor generates electrical energy when tensioning the conductorin the tension mode. The conductor stringing apparatus includes aprocessor and a motor controller in combination with the electric motor.The processor is switchable between a pulling mode and a tensioningmode. The processor outputs commands to the motor controller for controlof the electric motor. A plurality of batteries is used to apply powerto the electric motor and to receive power from the electric motor. Theprocessor applies electrical energy from the batteries to the electricmotor when in the pulling mode. The processor applies electrical energygenerated by the electric motor to the plurality of batteries when inthe tensioning mode. The processor limits electric motor torque andspeed based on operator commands for speed and torque in the pullingmode. The processor controls electric motor torque in the tensioningmode.

The three phase electric motor consumes electrical energy in the pullingmode. The Azure Dynamics Inc. motor controller converts direct currentinto alternating current according to a command message from the ParkerIQAN MD-3 controller and applies it to the three phase alternatingcurrent electric motor. Other three phase electric motors may be usedwith separate stand-alone motor controllers. Further, direct currentmotors may be used with appropriate controls.

The conductor stringing apparatus includes a resistor bank. Theprocessor applies electrical energy to the batteries and to the resistorbank. The processor periodically applies electrical energy to theresistor bank using a pulse width modulation control signal to a controlrelay. Alternatively, a solid state relay or an insulated gate bipolartransistor may be used. Pulse width modulation is employed wherein theprocessor controls the application of control signals to the gate of aninsulated gate bipolar transistor. The electric motor is an alternatingcurrent motor and the motor controller converts direct current batterypower to alternating current power. The motor controller convertsalternating current power into direct current power for application tothe battery or to the resistor bank. A charger for charging thebatteries from an external AC power supply is used to charge thebatteries at night or when the apparatus is not in use.

A battery temperature sensor generates a signal representative of thebattery temperature and inputs the battery temperature signal into theprocessor. The processor, using the battery temperature sensor, decideswhether to continue operation of the conductor stringing apparatus. Ifthe temperature of the battery is greater than 120° F. then operationfor the machine is discontinued. The battery temperature sensor may be athermocouple in engagement with the first negative battery post offifteen batteries connected in series.

A process for stringing a conductor is also disclosed and includes theinitial step of switching between pulling and tensioning modes asdesired. Further steps include controlling an electric motor using aprocessor and a motor controller. In the preferred embodiment the motorcontroller-motor combination are supplied by Azure Dynamics, Inc.Electrical energy from a plurality of batteries is consumed in theelectric motor when pulling a conductor in pulling mode. The electricmotor generates electrical energy and charges the plurality of batteriesunder certain conditions when tensioning a conductor in tensioning mode.Battery voltage is continuously monitored and when it reaches 198 voltsdc, the processor begins applying current to the resistor bank todissipate the energy in the form of heat. The processor limits theelectric motor torque and speed based on operator commands for speed andtorque in the pulling mode. The processor controls the electric motortorque in the tensioning mode and thus provides tension to the system.The process for stringing a conductor further comprises the steps ofdissipating excess electrical energy in a resistor bank when the voltagemeasured across the string of 15 batteries in series is equal or greaterthan 198 volts dc.

Accordingly, the process for stringing a conductor includes the steps ofmeasuring battery voltage, processing the battery voltage, and,controlling the dissipation of excess electrical energy in the resistorbank depending on the battery voltage. The step of controlling thedissipation of excess electrical energy in the resistor bank includesmodulating the pulse width of a control signal to a switching device inseries with the resistor bank. Preferably, the switching device is acontrol relay, an insulated gate bipolar transistor, or a solid stateswitching device. Application of the pulse width begins at 198 volts dcand continues and increases linearly up to and including 215 volts dc.

The process for stringing a conductor includes the steps of: monitoringbattery temperature; and, discontinuing the stringing operation when thebattery temperature exceeds a temperature limit of 120° Fahrenheit. Thebattery temperature is sensed from a thermocouple engaged with the firstnegative battery post of the string of 15 batteries.

It is an object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry which iscapable of energy recovery in the tensioning mode.

It is an object of the invention to provide an electric conductorstringing puller-tensioner which is of the multi-drum type for theelectric utility industry which is capable of energy recovery in thetensioning mode.

It is an object of the invention to provide an electric bullwheeltensioner for the electric utility industry which is capable of energyrecovery in the tensioning mode.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner with an energy management system for handlingenergy recovered in the tension mode.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry whichemploys pulse width modulation control in dividing energy betweenstorage batteries and a resistor bank for dissipating energy as heat.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry whichcontrols the speed of the reel between upper and lower torque values.

It is a further object of the invention to provide an electric bullwheeltensioner having positive control of the conductor or wire releasedunder tension.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry whichemploys an insulated gate bipolar transistor to implement pulse widthmodulation control of the resistor bank.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry whichemploys a solid state switch device to implement pulse width modulationcontrol of the resistor bank.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry whichemploys a control relay to implement pulse width modulation control ofthe resistor bank.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner apparatus which employs an alternatingcurrent motor controlled by a motor controller which converts directcurrent to alternating current.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner for the electric utility industry which isenvironmentally compatible and efficient.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner apparatus for the electric utility industrywhich is capable of energy recovery in the tension mode.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner apparatus for the electric utility industrywhich is capable of energy recovery in the tension mode and which iscontrollable based on battery bus voltage.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner apparatus for the electric utility industrywhich is capable of battery management and protection based on thetemperature of the batteries.

It is a further object of the invention to provide an electric conductorstringing puller-tensioner apparatus for the electric utility industrywhich employs a thermocouple attached to the negative post of thebattery connected to the negative battery bus.

Further objects of the invention will be understood when reference ismade to the drawings, description of the invention and claims whichfollow hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art illustration of a conductor stringing tensionerand puller.

FIG. 2 is a side view of the conductor stringing puller-tensioner of theinstant invention.

FIG. 2A is a view taken along the cross-sectional lines 2A-2A of FIG. 2.

FIG. 2B is a top view of the conductor stringing puller-tensioner of theinstant invention.

FIG. 2C is a cross-sectional view of the conductor stringingpuller-tension of the instant invention taken along the lines 2C-2C ofFIG. 2B.

FIG. 2D is a rear view of the conductor stringing puller-tensioner ofthe instant invention.

FIG. 2E is a sectional drawing taken along the lines of 2E-2E of FIG. 2Billustrating the battery securement.

FIG. 2F is a sectional drawing taken along the lines of 2F-2F of FIG. 2Billustrating the battery securement.

FIG. 2G is a perspective view of a battery and terminals.

FIG. 2H is an enlargement of a portion of FIG. 2G illustrating a screwin the negative most terminal.

FIG. 3 is a schematic ladder diagram of the 180 volt dc circuit whichincludes the batteries, the resistor bank, the three phase electricmotor and motor controller.

FIG. 3A is a schematic ladder diagram of the 12 volt dc circuit whichincludes the modules of the processor, various relays, and the InsulatedGate Bipolar Transistor.

FIG. 3B is a schematic illustrating: a processor module, rockerswitches, joystick, the voltage transducer monitoring the 180 volt dccircuit and the temperature transducer monitoring the batterytemperature.

FIG. 3C illustrates operation of the resistor bank and the pulse widthmodulation control signal.

FIG. 3D is a schematic ladder diagram of the 180 volt dc circuit whichincludes the batteries, the resistor bank, the three phase electricmotor, motor controller and an ultra-capacitor in parallel.

FIG. 4 is an illustration of the control panel.

FIG. 5 is a schematic diagram of the master start sequence of theconductor stringing puller-tensioner.

FIG. 5A is a schematic diagram of the motor control for the puller modeand the tension mode of the conductor stringing puller-tensioner.

FIG. 5B is a schematic diagram of the energy control in the tensionmode.

A better understanding of the drawings will be had when reference ismade to the description of the invention and the claims which followhereinbelow.

DESCRIPTION OF THE INVENTION

FIG. 1 is an illustration 100 of a conductor stringing tensioner 105 andpuller 104. Poles 101 and insulators 102 are illustrated as is aconductor pulling rope and conductor. Insulators 102 and stringerattachment 103 are illustrated in FIG. 1 as is the traveling ground.

FIG. 2 is a side view 200 of the conductor stringing puller-tensioner ofthe instant invention illustrating the resistor bank cabinet 201,control panel 211, and control box housings 211A, 211B. An operator ofthe device is protected by a protective screen 213 in the event of arope or conductor break under tension. Joystick 311A can be seen in FIG.2 protruding from the control panel. Batteries are secured in anundercarriage formed of channel 210 which is obscured from view in FIG.2 by battery skirt 202. Chain guard 203 protects a person fromentanglement with a chain (not shown) which operates between a smallsprocket (not shown) having 19 teeth per revolution and a large sprocket(not shown) having 84 teeth per revolution. Reel 205 upon whichconductor or rope is wound and reel shaft 204 are viewed well in FIG. 2.An outer frame 206 supports the operator and his or her chair as well asthe control panel. The main frame 207 supports the batteries, theelectric motor, the chain and the conductor/rope reel. Wheelcovering/wheel guard 203 is illustrated over wheels/tires. The outer andmain frames 206 are covered with metal plates enabling limited mobilityof the operator around the machine.

FIG. 2A is a view 200A taken along the cross-sectional lines 2A-2A ofFIG. 2. Batteries 220 are illustrated residing in channels 210. Channels210 include upwardly extending portions 220A. Motor controller 240A isillustrated in FIGS. 2A and 2C. FIG. 2B is a top view 200B of theconductor 230 stringing puller-tensioner of the instant invention.Flooring-battery covering 231, 231A, 231B and 231C are metal plateswhich are attached to the frame 206, 207 with screws or other attachmentmeans as shown in FIG. 2B. Battery hatch 211B allows access to battery319 which supplies start-up control power to the 12 volt dc circuitillustrated in FIG. 3A. The flooring-battery coverings reside over thebatteries and enable limited movement by the operator or maintenancepersonnel on the device. The batteries 220 are held in place bytie-downs 220B as illustrated in FIG. 2B.

The batteries may be replaced periodically for maintenance, repair orsubstitution of a fresh fully charged battery. Alternatively, anauxiliary trailer having thirty (30) fully charged 12 volt dc batteriesmay be placed in proximity to the conductor puller-tensioner as asupplemental energy source for longer pulls. The auxiliary batteries maybe coupled by using a socket and plug interconnection 320. Referencenumeral 320 diagrammatically illustrates the socket and plug andincludes necessary electrical interconnection and extensions to thesupplemental energy source.

FIG. 3 is a schematic ladder diagram 300 of the nominal 180 volt dccircuit which includes batteries 220, resistor bank 316, alternatingcurrent motor 240, and DMOC motor controller 240A. As for the resistorbank, it is a customized grouping of 15 individual resistors fromMilwaukee Resistor's Edge Power product line. Five (5) 2.75 ohmsresistors are in parallel with each other and form a set. Eachindividual resistor has a resistance of 2.75 ohms. Each set of resistorshas a resistance of 0.55 ohms and then three sets of the resistors areseries with each other for a total resistance of 1.65 ohms.

In FIG. 3, the batteries 220 are illustrated as being connected inseries. The power required by the three phase alternating current motor240 is approximately 27.767 Hp (20.7 Kw) and the required torque isapproximately 70,000 in-lbs. The reel sprocket (not shown) includes 84teeth per revolution and the motor sprocket (not shown) includes 19teeth per revolution. The sprockets reside within the chain guard 203and are not visible. The reduction of the gearbox is 15.3:1 and thetotal reduction is 67.642 which yields a torque requirement of 1,034. 8in-lbs (116.9 N-m). The required reel speed is 25 rpm which yields arequired motor speed of 1691 rpm. Different speeds, torques and gearreductions may be used as will be recognized by those skilled in the artwithout departing from the spirit and scope of the invention as setforth herein.

Still referring to FIG. 2B, conductor 230 is illustrated wound on reel205. Level winds 310B, 310C are illustrated in FIG. 3A which areresponsible for winding and unwinding the rope or conductor onto andoff-of reel 205 in an orderly fashion for efficient storage and payout.Adapter 241, multi-disc brake 242 and gearbox (gear reducer) 243 areillustrated in FIG. 2B.

FIG. 2C is a cross-sectional view 200C of the conductor stringingpuller-tensioner of the instant invention taken along the lines 2C-2C ofFIG. 2B with the reel and the three phase alternating current motorremoved. FIG. 2C illustrates the batteries 220 and their placement inthe channel 210 and the upwardly extending portion 220A of the channelFIG. 2D is a rear view 200D of the conductor stringing puller-tensionerof the instant invention.

FIG. 2E is a sectional view 200E taken along the lines of 2E-2E of FIG.2B illustrating the battery securement. Tie down rod 252 which may bepartially threaded rod or it may be threaded along its entirely length.Rod 252 is connected to the lower plate 254 which traverse channels 210.Nut 256 threads onto the tie down rod 252 and applies pressure to upperplate 220B against the batteries 220. Reference numeral 258 is the sidewall of the battery enclosure. FIG. 2F is a sectional view 200F takenalong the lines of 2F-2F of FIG. 2B illustrating the battery securement.

FIG. 2G is a perspective view 200G of a battery 220 and terminals 261,262. FIG. 2H is an enlargement 200H of a portion of FIG. 2G illustratinga threaded screw 265 in the negative most terminal 262. Referencenumeral 263 indicates the female threads within post/terminal 262.Thermocouple 264 may be affixed into engagement with the terminal 262 tomonitor the temperature of the battery.

Referring to FIG. 3, a schematic ladder diagram 300 of the nominal 180volt dc power system is illustrated. The voltage is referred to asnominal, meaning ordinary or expected. However the voltage across thebattery strings arranged in parallel with each other varies.Specifically, in the tensioning mode, if the voltage exceeds 198 voltsdc, then the 20 kW resistor bank 316 dissipates some of the energyaccording to the width of a pulse width modulation control signalapplied to a relay, solid state switching device, or an insulated gatebipolar transistor 349. Insulated gate bipolar transistors function as aswitch applying current to the resistor bank. Alternatively, contacts ofCR 5 may be used to control the application of the regenerated energyfrom the alternating current motor 240/DMOC controller/processor 240A tothe resistor bank.

Alternatively, an ultra-capacitor 391 may be used in parallel with thestring of batteries as illustrated on FIG. 3D. FIG. 3D and FIG. 3illustrate the same components only FIG. 3D includes the ultra-capacitorcapable of storing a large amount of charge. Ultra-capacitors orelectrochemical double layer capacitors (EDLC), are electrochemicalcapacitors that have an unusually high energy density when compared tocommon capacitors, typically on the order of thousands of times greaterthan a high-capacity electrolytic capacitor. Ultra-capacitors storeseveral are capable of storing many farads and some large commercialultra-capacitors have capacities of thousands of farads.

The three phase alternating current motor 240 (Azure Dynamics Inc. Modelno. AC55) and the DMOC motor controller 240A are supplied by AzureDynamics Inc. of Woburn, Mass. as a motor/controller package. The threephase alternating current motor is rated for 34 kW continuous power, 240N-m peak torque, and 8,000 rpm maximum speed. Other electric motor-motorcontroller packages may be used as those skilled in the art will readilyrecognize for different loads and machine characteristics.

Referring to FIG. 3, the high voltage power source is comprised ofthirty (30) deep cycle twelve (12) volt batteries 220 that are rated at150 amp-hours each. Fifteen (15), twelve (12) volt dc batteries 220 arewired in series to form the nominal 180 volt dc circuit. Two of thefifteen (15), twelve (12) volt battery strings are wired in parallelresulting in a 180 volt pack with a 300 amp-hour capacity. Trojan T-1275Plus, 12 volt dc, lead acid deep cycle batteries with 150 amp-hourcapacity are the preferred batteries 220. The batteries may be chargedin the tension mode as explained herein or they may be charged overnightor when the puller-tensioner is not in operation by employing charger305. Charger 305 is a Nivan Charger having an input source voltage of230 volts AC and can draw 30 Amps. Charger 305 outputs 180 volts DC. Ata voltage of 180 volts dc, the maximum current draw will be about 115amps to supply a motor load of 20.7 kW. The maximum current draw willonly be reached close to the end of a conductor stringing operation.

Voltage across the battery strings is monitored 370, 371 by a voltagetransducer illustrated in FIG. 3B. FIG. 3B is a schematic 300Billustrating: a processor module 306, rocker switches 311, joystick311A, voltage transducer 307 monitoring the 180 volt dc power system andthe temperature transducer 307A monitoring the battery temperature.Processor 306, 306A, 306B, and the DMOC motor controller 240A use CANprogram parameters for communication and processing. The voltagetransducer 307 monitors the voltage 370, 371 on terminals 323, 323A andoutputs (from terminal 326) a signal 338A which is input into andcommunicates with terminal 338 of processor 306. Processors 306, 306A,and 306B are an IQAN Parker Hannifin MD-3 processor. Processor 306includes terminal 339 which communicates with terminal 339A of module306A. Expansion module 306B includes terminals 359, 360 whichcommunicate with terminals 357, 358 of module 306A.

Voltage monitoring across the battery strings is important as thevoltage may increase during tensioning mode and the batteries arelimited as to how much energy or charge them may accept per unit timeand contain. The voltage transducer requires a 24 volt dc supply whichis supplied at pins 324, 312 of the transducer. Voltage converter 321 ispowered from the 12 volt dc logic circuit illustrated in FIG. 3A andsteps up the voltage to 24 volts dc for application to the voltagetransducer 307 and the temperature transducer 307A.

At a voltage of 198 volts dc as monitored across the nominal 180 volt dcpower supply circuit, the processor begins to modulate the amount ofenergy applied to the batteries and directs the energy to the resistorbank 316. At 198 volts DC the processor enables relay CR4 (SWITCH 349)which is output from terminal 346 of processor module 306B. Engineeringunits of volts dc across the battery string are converted by a CANprogram into counts for use within the CAN program. Energization ofrelay CR 4 closes contact CR4 which then allows current to flow in thecircuit and then applies power to energize relay CR5. Upon energizationof relay CR5, contacts CR5 in series with resistor bank 316 enablesapplication of current for the dissipation of energy in the resistorbank 316.

FIG. 3C illustrates 300C operation of the resistor bank pulse widthmodulation control signal. Specifically, reference numeral 349Eillustrates the battery voltage. Reference numeral 349D indicates theresistor power dissipation in Watts. Reference numeral 349C illustratesthe pulse width that corresponds to a particular voltage in the range of198 volts to 215 volts dc. Reference numeral 198 illustrates that whenthe voltage across the battery strings reaches 198 volts dc, a resistorpulse width modulation signal is applied to CR4 (or other switchingdevice) which controls relay contacts CR5 in series with the resistorban. The pulse width modulation signal begins at 198 volts dc andincreases linearly such that when 215 volts dc is reached theapplication of current to the resistor bank is constant, specifically,current is applied 100% of the time and 20 kW is dissipated in theresistor bank. The resistor bank dissipates 20 kW and is comprised ofsets of resistors which have a total resistance of 1.65 ohms.Specifically there are three sets of resistors in series with each sethaving five 2.75 ohm resistors arranged in parallel.

The invention includes a battery charging algorithm. Checks and balancesare used during tensioning for a safe battery pack charge. Voltage,current, and temperature are all used in the program to control it.Generally, charging current of a battery system is equal to Current/10,where Current is the 20 hr capacity of the system. Each battery stringemploys batteries having a 150 Amp-hour capacity. System capacity is 300Amp-hours because two battery strings are used so charging current isnominally 30 amps.

Current is not measured directly and externally to the DMOC motorcontroller 240A. Current is calculated from the power generated fromtensioning. We have inputs for speed and torque from the DMOC motorcontroller 240A, so horsepower is calculated from the formulaHorsepower=(ft-lbs*rpm)/5252. Horsepower is then converted Watts as 746Watts is approximately equal to 1 horsepower. Current in Amps is equalto Watts/Volts. The program uses torque, speed, voltage, current andtemperature for use in operating the resistor bank and charging thebatteries.

The program uses these values to decide if, and how much to pulse theresistors. If the charge rate is below 30 amps, and if the voltage isbelow 198 VDC, and if the temperature is below 118 degrees F., then theresistors are not used, or pulsed at zero percent.

There are three calculations made to determine the pulse rate of theresistors. They are all a percentage of the total resistive power. Theprogram picks the largest value to use as the actual PWM percentageemployed.

Formula 1: Current based pulse width modulation percentage.

A charge current of 30 amps is the nominal charging current. Potentialresistive power of the resistor bank is determined by squaring thevoltage and dividing by the resistance. Resistance of the resistor bankis a constant 1.65 ohms as explained elsewhere herein. Voltage of the180 volt circuit is not constant and is changing depending onoperational conditions and, as such, the potential power is alsochanging. Power is calculated from the tensioning. Power in thebatteries is 30 amps multiplied by the instantaneous voltage and mayrange from 5.4 kW to 6 kW, more or less. Power supplied to the batteriesis subtracted power from the power determined and generated by thetension and what remains, for example, the difference is the powerdissipated in the resistor bank. Power to be dissipated in the resistorbank is divided by the potential resistive power and is multiplied by100 to get a pulse width modulation percentage. This is the PWMpercentage determined using a current analysis.

Formula 2: Voltage based pulse width modulation percentage.

The calculation for voltage is much simpler than the calculation forcurrent. The battery voltage should not exceed 217 volt dc but needs tobe above 190.5 volts dc to charge the batteries. A linear calculationbetween 198 and 215 volts dc is used to determine a linear pulse widthmodulation percentage. In other words, the pulse width varies between 0and 100 percent as the voltage varies between 198 and 215 volts dc.Consequently, this is the formula that is used most often by the programbecause even if the charge rate is below 30 amps the voltage increases.

Formula 3: Temperature based pulse width modulation percentage.

The temperature of the batteries does not exceed 120 degrees F. When thetemperature reaches 118 degrees F., we equal the tension power andresistive power so that there is no charge or discharge in the batteriesand the resistors handle all of the current.

Again, these three formulas all calculate a percentage. The greatestpercentage is the one that the program uses.

Battery temperature is monitored by the battery transducer 307A.Engineering units of degrees Fahrenheit are converted into counts foruse in the CAN program. The temperature transducer circuit is suppliedby the voltage converter 321 with 24 volts dc across terminals 313, 329.A thermocouple input 315A is applied across terminals 314 and 315 of thetemperature transducer. The temperature transducer 307A outputs a signal318A on pin 318 which communicates with pin 330 on processor 306. Ifbattery temperature exceeds 120° F. then the machine is shut down andrelay contacts CR2 and CR3 in the 180 volt circuit open. Relay contactsCR2 and CR3 open as the output of pin 348 goes to zero and disablesrelay CR6. With relay CR6 de-energized, contacts CR6, CR6 opende-energizing relay contacts CR2, CR3 which result in the isolation ofthe battery strings 220 from electric motor 240/motor controller 240Aand from the dc-dc converter 317.

The 12 volt dc control circuit is supplied by the output 374, 375 of the180 vdc-12 vdc converter 317 illustrated in FIG. 3. Converter outputs374, 375 are also viewed in the upper portion of FIG. 3A. Referring toFIG. 3A, voltage isolating converter 309 supplies 12 volts dc fromunnumbered terminals and communication points 382, 383 to battery meter301 (FIG. 3) as indicated by communication points 382, 383 which in turncommunicate with pins 361, 365 of the battery meter. The battery meterincludes a shunt 351 which provides an input to pins 362, 363 of thebattery meter. Prescaler 301A is also used in connection with thebattery meter and communicates with terminals 361 and 364 respectively.

Referring to FIG. 3, alternating current three phase motor 240 and DMOCcontroller 240A are illustrated. Reference numerals A, B, C indicate thethree phase inputs to the windings of the motor. Twelve (12) volts dcare applied across terminals 369, 350 of the DMOC through communicationwith the 12 volt dc supply 374, 375 from the 180 volt dc-12 volt dcconverter 317. A CAN control message is applied to pins 366, 367 of theDMOC motor controller 240A. The CAN control message comes from processor306 pins 355, 356 of the IQAN MD-3 processor 306 and is interconnected378, 379 to the DMOC controller 240A. Similarly status messages arecommunicated from the DMOC motor controller 240A back to the processor306. The DMOC controller 240A applies an algorithm which depends on theoperational mode of the processor, for instance, whether the processoris in the tension mode or pulling mode. Further, processor 306 and itsmodules 306A, 306B are in communication with an interface 406illustrated in FIG. 4. Voltage, temperature, speed, torque as well asother parameters are displayed on the graphical interface 406.

In the pulling mode, lower torque and upper torque are set by theoperator. Speed is also operator controlled in a range of plus and minus0 to 100% with a dead band of +/−10%, but is limited by the values inputfor lower and upper torque. The speed regulator is active within thewindow given by the lower and upper torque limit. The speed set-point aswell as the toque limits are transmitted over CAN and may be modified bythe DMOC at a rate of 20 hz. If the speed set value can be reachedwithin the torque limits then speed regulation as commanded by theoperator speed input is achieved. If the limits are too restrictive, forexample, the lower torque and the upper torque are too close together,then the drive becomes essentially torque controlled.

In the tension mode, lower torque is set equal to upper torque and thetensioner acts as a classical torque resistance or tensioner.

Referring to FIG. 3B, rocker switch 311 communicates with pins 331, 332of processor 306. Joystick 311A includes right (increase) and left(decrease) torque pushbuttons. Depressing the right button 407Bcommunicates a torque increase signal to pin 332 of processor 306. SeeFIG. 4 for an illustration of the torque push button 407A, 407B.Depressing the left button 407A communicates a torque decrease signal topin 331 of processor 306. Source voltage is applied to pin 335 andground is applied to pin 334. The speed signal input, directionallyindicated as plus-minus 100% is applied to pin 333 of the processor 306.Speed input is controlled by the Joystick single axis forward andreverse movement as indicated in FIG. 4. A USB port communicates withpins 336, 337. The torque inputs to processor 306 are digital inputs andthe joystick speed on pin 333, the battery bus voltage on pin 338 andthe battery temperature on pin 330 are analog inputs. Torque and speedinputs are user controlled while operating the puller-tensioner.

FIG. 3A is a schematic ladder diagram 300A of the 12 volt dc circuitwhich includes the modules of the processor 306A, 306B, relays CR1, CR4,CR5, CR2, CR3, level wind actuator motors 310, 310A and switch 349.Battery 319 supplies energy for the control logic set forth in FIG. 3Abefore the puller-tensioner is started. A DC-DC converter 317 keeps the12 volt dc battery 319 charged via interconnection points 374, 375 ofthe converter 317 and interconnection points 380, 381 of the 180 volt dccircuit. Key switch 302 energizes relay CR1 which is a permissive toapplication of power to the isolating DC-DC converter for the batterymeter 301, the level wind actuators 310, 310A and the processor 306,306A, 306B. Switch 302 is also viewed on FIG. 4 and is labeled systemenable.

Processor module 306A is powered by the 12 volt dc bus at terminals 352,354 as illustrated in FIG. 3A and socket relay indicates that theprocessor is active. Similarly processor module 306B is supplied withpower at pins 340, 345. RS 232 communication is accomplished atterminals 343, 344 of module 306B. An address tag is communicated atterminals 341, 342 of module 306B. Processor 306B drives the brakedisable relay which controls the electric brake 242 contained within theelectric motor-electric motor brake housing. Electric brake 242 isapplied when the electric motor 240 is commanded to shutdown when thebattery temperature exceeds 120° F.

Still referring to FIG. 3A, control relays CR2 and CR3 are enabled whenrelay CR6 is energized closing contacts CR6, CR6. Control relay CR6 isenergized when the joystick 311A is centered or it is within its deadband zone (plus-minus 10% of being centered) and the holding electricbrake 242 is off. When CR6 is energized two sets of contacts CR6 areenabled which, in turn, enable CR2 and CR3 which then energizes the 180volt dc circuit upon the closure of contacts CR2, CR3 as illustrated inFIG. 3.

FIG. 4 is an illustration 400 of the control panel 408. Control panel408 is viewed by the operator and informs the operator as to severalimportant parameters. First, key 302 enables the system. Battery meter301 indicates the voltage across the battery strings. Brake pressure 404is the pressure applied by the brake within the motor-brake assembly.The electric brake can be manually applied by the operator throughtoggle brake arm 405. The direction 403 of the level wind iscontrollable as is viewed in FIG. 4. Joystick 311A and torque increase407B and torque decrease 407A buttons are illustrated. Indicia 420instructing the operator as to operation of the joystick (payout andpull-in) and the torque inputs is applied to the control panel 408.

Master control interface 406 is illustrated in FIG. 4 having a displayscreen for conveying information to the operator. F1, designated byreference numeral 430, is depressed to enter the puller mode. F2,designated by reference numeral 431, is depressed to enter thetensioning mode. Button F3, designated by reference numeral 432, isdepressed to enter the diagnostic mode.

In the pulling mode, input and actual speed and torque are displayed.Battery temperature and voltage are also displayed. The operator mayalso reset the torque by depressing one of the arrow buttons on thecontroller (processor) interface 406. The controller temperature is alsoindicated.

In the tension mode, input and actual speed and torque are displayed.Battery temperature and voltage are also displayed. Also, in the tensionmode the percentage of the pulse width modulation being applied is alsodisplayed. A green light is displayed on the processor screen indicatingthat the controller is operating in the tension mode. The controllertemperature is also indicated.

In the diagnostic mode the input and output speed and torque aredisplayed in parametric indications of the CAN program.

FIG. 5 is a schematic diagram 500 of the master start sequence of theconductor stringing puller-tensioner. Reference numeral 501 indicatesthe master start sequence. The first query 502 is whether the joysticklever is centered. If the joystick lever is not centered, the operatormust center it to enable the 180 volt dc circuit. So, in other words,the joystick must be centered plus or minus 10% as previously indicatedas a permissive to starting the puller-tensioner. Next, the holdingbrake must be off and a query 503 in this regard is represented in theflow chart. If the brake is off then the 180 volt dc circuit can beenabled by energizing control relays CR6, CR2, and CR3. If the holdingbrake is not off, it must be positioned in the off position. To enablethe 180 volt dc circuit, relays CR6, CR2 and CR3 are energized.Therefore, the CAN program requires the joystick to be centered +/−10%and the motor brake 242 must be off.

FIG. 5A is a schematic diagram 500A of the motor control 505 for thepuller mode and the tension mode of the conductor stringingpuller-tensioner. If the machine was automatically shutdown 506 then theinput speed is automatically set to zero 507. If the machine was notautomatically shut down then the input speed and direction is determined508 by the operator positioning the joystick lever. Upper and lowertorque is then determined and set by the operator by pressing right 407Bor left 407A joystick buttons 509.

If the machine is in the puller mode 510 then a query 511 is present asto whether or not the torque reset button has been pressed. If thetorque reset button has not been pressed then the lower torque is set tozero 515 and the upper torque remains as set in step 509. If the torquereset button has been pressed then the reset is confirmed 512, 513through messages displayed on the interface 406 and the upper torque isset to zero 514 and the lower torque is also zero 515. For thiscondition, where the pulling mode is active and the reset button ispressed the upper and lower torque are both set to zero. If the torquebutton has not been depressed then in the pulling mode the motor isoperating with an upper torque set by the operator and a lower torqueset at zero.

Still referring to FIG. 5A, in tension mode, the lower and upper torqueare equal 516 and determined by the upper torque setting 509.

Still referring to FIG. 5A, next, regardless of tension or pulling mode,the input speed, upper torque, and lower torque values are convertedinto CAN program parameters 517 and transmitted to the motor controllervia the CAN bus 518. The input speed and upper torque values aremathematically processed 519 for display 520 as input values on theinterface 406. The processor receives actual speed and torque values 521from the DMOC motor controller 240A and mathematically processes them522 and displays them as actual values 522, 523.

FIG. 5B is a schematic diagram 500B of the energy control and managementsystem in the tension mode 524 resulting from depressing the tensionfunction key 525. In the tension mode the joystick lever must be pushedback to plus or minus 10% and the tension mode green lamp is displayed527. Battery temperature from the controller is received by theprocessor via the CAN bus 528 and is mathematically processed 529 fordisplay in engineering units of volts dc 530. The resistor bank pulsewidth modulation duty cycle is calculated 531 depending on the voltage.The resistor bank is enable by the pulse width duty cycle as dictated byCR 5 532. The pulse width modulation duty cycle as a percentage isdisplayed 533 on the graphical interface. Battery temperature ismeasured 534 and mathematically processed 535 and displayed 536 inengineering units. If the battery temperature is greater than 120° F.then the holding brake is applied 538 and the machine is shut down 539.If the temperature is less than 120° F. then the temperature isprocessed for display in engineering units 528, 529 and the steps arerepeated.

The input for speed is an analog signal originating from abi-directional, single-axis joystick on the control panel. The signalthat it sends is a voltage ranging from 500-4500 mV when the joystick isin its full back or full forward position, respectively. This voltagesignal is received by the Parker IQAN MD3 control module/processor 306and is represented by the voltage-in channel (pin 333) labeled Joystick.In this channel the voltage signal is converted to a percentage thatranges from −100 to 100. This value is converted into CAN programparameters. First, a dead zone is created by specifying that between−10% and +10% the value will be zero. Second, the range is converted tothe CAN parameters needed by the Azure Dynamics, Inc. motor controller240A. This CAN parameter value is 670 for max speed.

The inputs for torque are the two buttons 407A, 407B on the top of thejoystick 311A. Each button inputs to channel (pins 331, 332) onprocessor 306. The right button 407B is connected to pin 332 to raisetorque and the left button is connected to pin 331 to lower torque. Anevent-counter counts the amount of times the user presses the joystickbuttons, adding when the right button 407B is pressed and subtractingwhen the left button 407A is pressed. The user reaches maximum torqueafter 100 clicks of the right button. The value for maximum torque inCAN parametric form is 1146.88. To reach this value in 100 clicks, eachcount of the Joystick is multiplied by 11.4688. This value is sent tothe parameter-out channel and is the upper torque limit. Theparameter-out channel, lower torque limit is either zero, as is the casewhen pulling, or is equal to the upper torque limit, as is the case whentensioning.

Three parameter-out channels, speed control, upper torque limit, andlower torque limit, are attached to the generic frame out channel,control message. The control message is sent to the Azure Dynamics Inc.motor controller 240A where it interprets the inputs and regulates themotor speed and torque accordingly. The motor controller 240Acommunicates status messages back to the processor 306 for processingand display on display 406.

The algorithms implemented by the processor described herein are setforth by way of example only. It is specifically contemplated thatdifferent algorithms may be used for the control of, for example, theelectric motor(s), tension, speed, torque and safety and otherparameters without departing from the spirit and scope of the claimedinvention.

REFERENCE NUMERALS

-   A, B, C—motor phases-   F1—puller function key-   F2—tension function key-   F3—diagnostic function key-   CR1—actuator relay and relay contacts-   CR2—180 Vdc relay and relay contacts-   CR3—180 Vdc relay and relay contacts-   CR5—resistor bank relay and relay contacts-   100—prior art schematic of conductor stringing process-   101—pole-   102—insulator-   103—stringer attachment-   104—puller-   105—tensioner-   200—side view of puller-tensioner-   200A—cross-sectional view taken along the lines 2A-2A of FIG. 2-   200B—top view of puller-tensioner-   200C—cross-sectional view taken along the lines 2C-2C of FIG. 2-   200D—rear view of the puller-tensioner-   200E—sectional view taken along the lines of 2E-2E of FIG. 2B.-   200E—sectional view taken along the lines of 2F-2F of FIG. 2B.-   200G—perspective view of battery and terminals-   200H—enlargement of a portion of FIG. 2G-   201—resistor bank cabinet-   202—battery skirt-   203—chain guard-   204—reel shaft-   205—reel-   206—frame (frontal portion)-   207—main frame-   208—wheel covering/wheel guard-   210—channel forming battery supports-   211—control panel-   211A—control box housing-   211B—battery hatch-   212—joystick-   213—protective screen-   220—battery-   220A—upwardly extending portion of channel-   220B—battery upper plate for tie down-   230—conductor-   231, 231A, 231B, 231C—flooring/battery cover-   240—three phase electric motor-   240A—DMOC motor controller-   241—adapter-   242—multi-disc brake-   243—gearbox-   252—tie down rod which may be partially threaded-   256—nut which threads onto the tie down rod-   254—lower plate affixed to and traverses channels-   258—side wall of battery enclosure-   261, 262—battery terminals 261, 262.-   263—female threads within terminal 262-   264—thermocouple 264 affixed into engagement with the terminal 262-   300—180 volt ladder diagram-   300A—12 volt ladder diagram-   300B—joystick, temperature and voltage transducer-   300C—pulse width modulation schematic-   301—battery meter-   301A—prescaler-   302—keyed switch-   305—charger-   306—processor, Parker Hannifin, IQAN MD3-C1-   306A—IQAN module-   306B—IQAN Expansion Module-   307—voltage transducer-   307A—temperature transducer-   308—180 volt battery-   309—isolating converter for battery monitor-   310, 310A—level wind actuator motors-   311—torque rocker switch inputting to IQAN MD3-C2-   311A—joystick-   312—negative (−) 24 volts dc-   313—positive (+) 24 volt dc supply to voltage transducer-   314—thermocouple attached to first negative battery terminal-   315—thermocouple attached to second negative battery terminal-   315A—thermocouple-   316—resistor bank-   317—180 volt dc−12 volt dc+converter-   318—output terminal of temperature transducer-   318A—output (volts dc) to processor representing battery temperature-   319—12 volt battery-   320—battery interconnection with motor circuit, resistor bank and    meter-   321—voltage converter 12/24 volt dc-   323—positive (+) 180 volt dc supply-   323A—negative (−) 180 volt dc supply-   324—positive (+) 24 volts dc-   325—socket relay-   326—output (volts dc) to processor representing voltage temperature-   329—negative (−) 24 volt dc supply to voltage transducer-   330—battery temperature input terminal-   331—lower torque pushbutton terminal-   332—raise torque pushbutton terminal-   333—ground-   334—common-   335—source voltage joystick (positive 12 volt dc)-   336—USB-   337—USB-   338—180 volt dc bus voltage measurement/input-   338A—voltage transducer-   339, 339A—communication between IQAN MD3-C1 and IQAN MD3-C2-   340—positive (+) 12 volt dc-   341—address tag-   342—address tag-   343—RS 232 communication terminal-   344—RS 232 communication terminal-   345—negative (−) 12 volt dc supply-   346—digital output enabling CR5-   347—digital output enabling brake-   348—digital output enabling 180 volt dc power to motor/DMOC-   349—Switch, i.e., Relay, IGBT (Insulated Gate Bipolar Transistor),    or other solid state device-   349C—pulse width modulation signal-   349D—resistor power dissipation in % and Watts-   349E—measured battery voltage, volt dc-   349G—198 volts dc-   350—negative (−) input terminal-   351—shunt-   352—positive (+) 12 volt dc voltage input to IQAN MD3-C1 processor-   353—socket relay terminal on IQAN MD3-C1-   354—negative (−) 12 volt dc voltage input to IQAN MD3-C1-   355—communication terminal to DMOC motor controller-   356—communication terminal to DMOC motor controller-   357—communication terminal to IQAN XA2-   358—communication terminal to IQAN XA2-   359—communication terminal to IQAN MDC3-C1-   360—communication terminal to IQAN MDC3-C1-   361—negative (−) 12 volt dc terminal to battery meter and prescaler-   362—shunt terminal connection-   363—shunt terminal connection-   364—prescaler connection-   365—positive (+) 12 volt dc terminal to battery meter and prescaler-   366—CAN communication-   367—CAN communication-   368—ground-   369—positive (+) 12 volt dc terminal-   370, 371—voltage transducer power supply-   374, 375—12 volt dc output of converter-   378, 379—CAN communication-   382, 383—12 volt dc supply to battery monitor-   391—battery-   391A—ultra-capacitor-   400—control panel-   402—key/switch-   403—level wind control-   404—brake pressure indicator-   405—brake control-   406—master control interface-   407A—torque control decrease-   407B—torque control increase-   420—directional indication-   430—puller mode push button, F1-   431—tension mode push button, F2-   432—diagnostic push button, F3-   500—180 volt dc control schematic flow chart-   500A—motor control schematic flow chart-   500B—tension mode schematic flow chart-   501—master start-   502—joystick lever centered?-   503—holding brake off?-   504—enable 180 volt dc circuit, energize CR6, CR2 and CR3-   505—motor control-   506—puller/tensioner automatically shutdown-   507—input speed=0 if machine was automatically shutdown-   508—input speed and direction (pay-out or pull-in) joystick    controlled-   509—upper torque set by depressing right button (increase) or left    button (decrease)-   510—tension mode?-   511—torque reset button pressed?-   512—display confirmation message of torque reset?-   513—user confirmation of torque reset?-   514—reset upper torque to zero-   515—lower torque equals zero-   516—lower torque equals upper torque in tension mode-   517—conversion of speed and upper and lower torque to motor    controller-   518—transmit converted values to DMOC motor controller using CAN Bus-   519—mathematically process input and upper torque values for display-   520—display input speed and torque values-   521—receive actual speed and torque values from DMOC motor    controller using CAN Bus-   522—mathematically process actual speed and torque values for    display-   523—display actual speed and torque values-   524—tension mode-   525—tension function key F2 pressed?-   526—joystick lever pulled back?-   527—enter tension mode, display green lamp-   528—receive battery voltage from DMOC motor controller via CAN Bus-   529—mathematically process battery voltage for display-   530—display batter voltage-   531—calculate resistor bank PWM duty cycle-   532—enable resistor bank, energize CR5-   533—display PWM duty cycle as a %-   534—measure batter temperature-   535—mathematically process battery temperature for display-   536—display battery temperature-   537—is battery temperature greater than 120 degrees Fahrenheit?-   538—apply holding brake-   539—shut machine down

Those skilled in the art will recognize that the invention has been setforth by way of examples. As such, changes may be made to the inventionhas described and disclosed herein without departing from the spirit andthe scope of the invention as claimed hereinbelow.

1-10. (canceled)
 11. A process for stringing a conductor, comprising thesteps of: switching between pulling and tensioning modes; controlling anelectric motor using a processor and motor controller; consumingelectrical energy from a plurality of batteries in said electric motorwhen pulling a conductor; and, generating electrical energy with saidelectric motor and charging said plurality of batteries when tensioninga conductor.
 12. A process for stringing a conductor as claimed in claim11, further comprising the steps of: limiting electric motor torque andspeed based on operator commands for speed and torque in said pullingmode; and, controlling electric motor torque in said tensioning mode.13. A process for stringing a conductor as claimed in claim 12, furthercomprising the steps of: dissipating excess electrical energy in aresistor bank.
 14. A process for stringing a conductor as claimed inclaim 13, further comprising the steps of: measuring battery voltage;processing said battery voltage; and, controlling said dissipation ofexcess electrical energy in said resistor bank depending on said batteryvoltage.
 15. A process for stringing a conductor as claimed in claim 14wherein said step of controlling said dissipation of excess electricalenergy in said resistor bank includes modulating the pulse width of acontrol signal to a switching device in series with said resistor bank.16. A process for stringing a conductor as claimed in claim 15 whereinsaid switching device is an insulated gate bipolar transistor.
 17. Aprocess for stringing a conductor as claimed in claim 15 whereinapplication of said pulse width begins at 198 volts dc.
 18. A processfor stringing a conductor as claimed in claim 16 wherein application ofsaid pulse width begins at 198 volts dc.
 19. A process for stringing aconductor as claimed in claim 11 further comprising the steps of:monitoring battery temperature; and, discontinuing stringing of saidconductor when said battery temperature exceeds a temperature limit. 20.A process for stringing a conductor as claimed in claim 17 wherein saidtemperature limit is 120° Fahrenheit.
 21. A process for stringing aconductor as claimed in claim 19 wherein said battery temperature issensed from a thermocouple engaged with the first negative battery post.22-24. (canceled)
 25. A process for stringing a conductor as claimed inclaim 13, further comprising the steps of: calculating total power fromtension in the conductor or rope; measuring battery voltage andmultiplying it by the battery current determining power supplied to thebatteries; subtracting power supplied to the batteries from said totalpower and determining power to be dissipated in said batteries anddividing said power to be dissipated by the potential resistive power ofapproximately 20 kW and multiplying by 100 to arrive at the percentageof pulse width modulation to be applied.
 26. A conductor stringingapparatus as claimed in claim 2 further comprising an ultra-capacitor inparallel with said batteries.
 27. A process for stringing a conductor asclaimed in claim 11, further comprising the steps of: generatingelectrical energy with said electric motor and charging anultra-capacitor when tensioning a conductor.